Hộp số 10 cấp SPTS0130807 132

SECTION l GENERAL INFORMATION SECTION VI RANGE CASE DISASSEMBLY SECTION VII MAIN CASE DISASSEMBLY CASE & SHIFT FORKS EXPLODED DRAWING 22 MAIN CASE OPTILUBE EXPLODED DRAWING 24 MAIN CA

Trang 1

Service Manual

9/10 Speed Transmission

PSO150-9A

Trang 2

9 SPEED TRANSMISSION

This symbol indicates a potentially hazardous

situation If the instructions aren't followed, the result

could be death or serious injury.

This symbol indicates that you must do some thing in

order for the transmission to function properly For

example, you must use only one gasket underneath

the shift tower If it is eliminated, or more than one

gasket is used, binding can occur This would prevent

proper shifting of the transmission and could damage

the unit.

This symbol indicates that you must NOT do

something in order to avoid damaging the

transmission For example, you must not use sealant

underneath the shift tower Using sealant underneath

the tower will prevent proper interlock functioning and

could damage the unit.

SAFETY FIRST

Carefully read this service manual

before beginning any work on your

Spicer transmission.

Throughout this literature, you will see symbols that warn of

potential physical danger or product damage if the

accompanying instructions aren't followed Here are the

symbols and their meanings.

Be sure you understand all procedures and instructions in

this manual before you begin working on your Spicer

Transmission If you have any questions, contact your

Spicer® Transmission representative.

The information in this service manual was current at the time of publication

This information is subject to change at any time without notice

Use a hoist whenever lifting the transmission or shaft assemblies Using a hoist can help prevent

muscle strain or other possible injuries.

Always wear safety glasses when working on the transmissions to help prevent possible eye injury due to small parts (such as snap rings) or metal chips that may fly up unexpectedly during a teardown or rebuild.

Be careful when picking up gears or other sharp components If you aren't careful, you could cut your

hands Consider wearing heavy cloth gloves or covering sharp objects with shop towels before picking them up.

When draining the transmission prior to working

on it, be careful to let the unit cool down first

Otherwise, hot transmission fluid could cause burns.

General Safety Precautions

2 GENERAL INFORMATION

Trang 3

SECTION l GENERAL INFORMATION

SECTION VI RANGE CASE DISASSEMBLY

SECTION VII MAIN CASE DISASSEMBLY

CASE & SHIFT FORKS EXPLODED DRAWING 22

MAIN CASE OPTILUBE EXPLODED DRAWING 24 MAIN CASE GEARS EXPLODED DRAWING 25

SECTION VIII COUNTERSHAFT DISASSEMBLY & REASSEMBLY 29

SECTION IX CLEANING & INSPECTION PROCEDURES 30

TABLE OF CONTENTS

3

Trang 4

Simple Shift Patterns

Gear Ratio O/D Ratio

8 4

9 5

7 3

Pro-Shift Nine Speeds

Model Weight * Clutch Housing Lube Capacity Overall Length PTO Speed (% of engin)

625-635 lbs Iron SAE 18 pints 28.96”

Trang 5

GENERAL INFORMATION

10 SPEED

4B

Trang 6

GENERAL INFORMATION

Section I

Wrench Torque(ft Ibs.)TORQUE SPECIFICATIONS FOR NUTS AND CAP SCREWS

Nom Thread Size PART NAME NON-LOCKING TYPE LOCKING TYPE

5

Trang 7

How to Shift the Spicer

PSO100-10S,PSO125-10S,

PSO140-10S & PSO150-10S

Transmissions

3 (A) Release the tractor parking brakes and trailer parking

brakes where applicable

(B) Release the clutch pedal gradually to full position

(C) Depress the throttle to start the vehicle moving

4 (A) After attaining optima! speed in 1st gear,

(B) Depress the clutch pedal

(C) Move the gear shift lever to neutral

(See "Double Clutching: Upshifting’)

(D) Then move the gear shift lever to 2nd gear

5 (A) Continue the above procedures through 5th gear position

6 (A) To continue upshifting (6th gear through 10th gear)(B) Preselect high range on the range selector

(C) Depress the clutch pedal

(B) Move the gear shift lever from the 5th gear position

to neutral (See "Double Clutching: Upshifting")(E) Then move the gear shift lever into 6th gear position

8 (A) Continue these procedures for 8th - 10th gear positions

Downshifting

Downshifting is actually just the reverse of upshifting

(see "Double Clutching: Downshifting")

When selecting a starting gear, if you have a butt-tooth condition, gradually release the clutch so the drive gear can rotate to align the gear clutching teeth to complete the shift

Starting Vehicle From a Stop

1 (A) With the gear shift lever in neutral,

(B) Clutch pedal depressed,

(C) And brakes set,

(D) Start the engine Allow it to build to maximum air pressure

2 (A) With the clutch pedal fully depressed to engage the clutch

brake (see "Clutch Brake"),

(B) Position the range selector to low range Move the gear

shift lever into 1st gear position

MODELS:

PS95-9A/PS125-9A/PS140-9A PSO125-9A/PSO140-9A/PSO150-9A

Trang 8

How to Shift the Spicer

PSO100-10S,PSO125-10S,

PSO140-10S & PSO150-10S

Transmissions

3 (A) Release the tractor parking brakes and trailer parking

brakes where applicable

(B) Release the clutch pedal gradually to full position

(C) Depress the throttle to start the vehicle moving

4 (A) After attaining optima! speed in 1st gear,

(B) Depress the clutch pedal

(C) Move the gear shift lever to neutral

(See "Double Clutching: Upshifting’)

(D) Then move the gear shift lever to 2nd gear

5 (A) Continue the above procedures through 5th gear position

6 (A) To continue upshifting (6th gear through 10th gear)(B) Preselect high range on the range selector

(C) Depress the clutch pedal

(B) Move the gear shift lever from the 5th gear position

to neutral (See "Double Clutching: Upshifting")(E) Then move the gear shift lever into 6th gear position

8 (A) Continue these procedures for 8th - 10th gear positions

Downshifting

Downshifting is actually just the reverse of upshifting

(see "Double Clutching: Downshifting")

When selecting a starting gear, if you have a butt-tooth condition, gradually release the clutch so the drive gear can rotate to align the gear clutching teeth to complete the shift

Starting Vehicle From a Stop

1 (A) With the gear shift lever in neutral,

(B) Clutch pedal depressed,

(C) And brakes set,

(D) Start the engine Allow it to build to maximum air pressure

2 (A) With the clutch pedal fully depressed to engage the clutch

brake (see "Clutch Brake"),

(B) Position the range selector to low range Move the gear

shift lever into 1st gear position

MODELS:

6

6B

Trang 9

Double Clutching

Upshifting: The normal double clutching technique is

suggested When you want to shift, depress the clutch and

move the lever to neutral Engage the clutch and allow the

engine RPM to drop so engine speed and driveline speed

match Depress the clutch and move the lever into gear

Engage the clutch and accelerate as conditions permit.

Downshifting: Downshifting is the reverse of upshifting As the

engine approaches the shift point (start the downshift

approximately 50 -100 RPM above the shift point), depress

the clutch and move the lever to neutral Engage the clutch

and raise the engine RPM until the engine and driveline

speeds are equal (normally, governed speed) Depress the

clutch, then shift into the next lower gear Engage the clutch.

Skip Shifting

Experienced drivers sometimes want to skip some of the

ratios This is acceptable However, you should do this only

when operating conditions allow Your speed, the load, and

The road type and condition should be considered.

Double clutch when shifting This will help

components match speed better during shifts and will help ensure proper engagement.

Downshift through all gear speeds when you are slowing down Chassis and trailer brake life can be

increased by doing this.

Do not force the shift since this can cause damage

to clutch collars and clutching teeth Use steady

force on the shift lever to complete shifts.

Do not coast in neutral The vehicle could lose RPM’s

during coasting and you may not be able to shift back into the proper gear.

Do not downshift at road speeds that are too fast

This could prevent proper gear engagement and could damage clutching teeth.

Do not tow vehicles without first pulling the axles

or disconnecting the driveshaft If you tow the

vehicle without doing this, you can damage drive train components because the system lubrication is inadequate when the vehicle is towed.

GENERAL INFORMATION

Section I

MODELS:

Reminders

7

tech line 800-401-9866 www.ttcautomotive.com

PS 9/10

Trang 10

AIR LINE PIPING DIAGRAM

Maintenance

MODELS:

8

PS 9/10

Trang 11

Use only petroleum-based solvents to clean parts Other types of

solvents could damage filter components and affect proper operation

Blow air through the filter (inside and outside) to dislodge surface

contaminants Otherwise, these contaminants could affect proper filter

operation and lead to equipment damage

Do not disassemble the regulator section (9): it is not field-repairable If

it is damaged, replace it

MAINTENANCE

Section II

MODELS:

1 Clean or replace the filter element (7) every 6-12 months, or whenever slow

shifting is encountered The element should be replaced after three cleanings If

regulator malfunction is indicated, replace the entire unit

2 To service the filter section, shut off the air pressure Unscrew the bowl (1) and

remove the O-ring (2) Unscrew the stud (4) Remove the louver (5), upper gasket

(6), element (7),

and lower gasket (8) from the stud Do not disassemble the regulator section (9)

3 After cleaning, inspect the parts carefully Replace any damaged parts

4 Reassemble the unit by first installing the element (7) on the stud (4), so that the

large end of the internal taper (thinnest wall section) is toward the hex on the stud

Torque the stud to 5 - 10 Ibs inch

5 Apply a wipe coat of Dow Corning DC7 Silicone Grease (or equivalent) to the

O-ring (2) seating surfaces on the regulator (9) and bowl (1) Apply a light, even coat

of Molykote "G" (or equivalent) to the bowl threads Torque the bowl to 5 -10 Ibs

inch If the drain valve (3) was removed, reinstall it and torque it to 10-15 Ibs Inch

Trang 12

CAUTION: To ensure proper lubrication and

operating temperatures in this unit, the proper

lubricants must be used Correct oil levels must be

maintained Spicer recommends using only lubricants

produced by reputable, well-known suppliers If you want to

use a lubricant not specified below, please contact your local

truck dealer to determine whether the lubricant is suitable for

your purposes.

Recommended Lubricants

The lubricants listed below are recommended for use in all

Spicer mechanical transmissions, auxiliaries, and transfer

cases.

Oil Changes

Many factors influence oil change periods Changes should

be scheduled at three years or 250,000 miles with synthetic

engine oil for normal over-the-highway operations

Off-highway use usually requires an oil change every 1,000

hours The oil level in the transmission should be checked

every 5,000 miles (8,045 km) on-highway, or every 40 hours

in off-highway operation When it is necessary to add oil,

Spicer recommends that types and brands of oil not be

mixed The correct oil level in this transmission is established

by the filler plug opening.

Refill

First, remove all dirt around the filler plug Then refill the transmission with new oil Use the grade recommended for the existing season and prevailing service The lubricant should

be level with the oil fill plug located on the left side of the transmission case.

Overfilling:

CAUTION: Do not overfill the transmission This

usually results in oil breakdown due to excessive heat and aeration from the churning action of the gears Early breakdown of the oil will result in heavy varnish and sludge deposits that plug up oil ports and build up on splines and bearings

MAINTENANCE

Section II

MODELS:

All CD 50 Synthetic engine oil meeting MIL-L-2104 D

or MIL-L-46152 B, API-SF or API-CD

Oil Cooler

See standard application requirements.

10

PS 9/10

Trang 13

Important Procedure

To locate and correct unit power or auxiliary transmission

troubles, a systematic procedure should be followed.

Road test whenever possible Mechanics usually get second-

or third-hand reports of trouble experienced with the unit

These reports do not always accurately describe the actual

conditions Sometimes symptoms seem to indicate trouble in

the transmission, while actually the problem is with the axle,

driveshaft, universal joints, engine or clutch This is especially

true of noise complaints Therefore, before removing the

transmission or related components to locate trouble, road

test to check the possibility of trouble in other closely

associated units Road testing is most effective when the

mechanic drives the vehicle However, riding with the driver

can be very informative.

Check Functioning

Prior to Disassembly

If a remote control is used, a careful check of the remote and

connecting linkages (and their adjustment) must be made

The remote unit must be in good working order if the

transmission is expected to shift satisfactorily.

Many times, the answer to the trouble is apparent when the

unit is inspected prior to disassembly But this evidence is

often lost when the parts are separated If possible, check the

unit prior to disassembly Bear in mind that a careful

inspection of the unit should be made as each disassembly

step is performed.

Inspect Thoroughly During Disassembly

It is poor practice to disassemble a unit or the complete transmission as quickly as possible without examining the parts The mechanic may completely disassemble a unit and fail to find the cause of the trouble, unless he examines the parts After the transmission is disassembled, check the lubricant for foreign particles This is a source of trouble often overlooked during the disassembly.

Repair or Replace Worn Parts

Many times the parts or critical adjustments causing the trouble are not replaced or corrected because the mechanic only inspects and replaces parts that have failed completely All pieces should be carefully examined because broken parts are often just the result not the cause of the problem All parts that are broken or worn and no longer meet specifications should be replaced

Also, parts that are worn to the extent that they do not have a long service life remaining should be replaced Replacing these parts now will avoid another teardown on the unit in the near future Also at this time, make the recommended changes or modifications to bring the transmission up to date and increase the service life of the unit.

GENERAL DISASSEMBLY

Section III

MODELS:

11

8

PS 9/10

Trang 14

Rebuild Facilities

A suitable holding fixture or overhaul stand with a hole for the input

shaft is desirable

For easier working conditions, table height should be 28 - 30

inches A light chain hoist should be used to handle the mainshaft

and countershafts during removal and reassembly procedures

Cleanliness

Transmissions should be steam cleaned prior to disassembly Seal

all openings before steam cleaning to prevent entry of dirt and

water which can damage serviceable parts

Dirt is abrasive and will cause premature wear of bearings and

other parts Spicer suggests that mechanics have a wash tank

available to clean parts just prior to reassembly

Bearings

When a transmission is removed at relatively low mileage, bearings

should be removed with pullers designed for this purpose Wrap the

bearings to keep out dirt Clean, inspect, and lubricate all bearings

just prior to reassembly If accumulated mileage is over 150,000

miles, we suggest that all bearings be replaced If bearings are

worn or damaged, always replace them regardless of mileage

Read this section before starting the

detailed disassembly procedures Follow

procedures closely to ensure proper

Serious damage can be done internally to bearings, thrust faces and washers by hammering on external parts In most designs, when the yoke/flange locknuts are tightened and secure, the internal bearings and gears are in proper location When the yoke/flange is driven on the shaft, however, two conditions can exist

(A) If the bearing fit is tight on the shaft, usually the bearings will brinell as they must absorb the pounding force

(B) If the bearing fit is loose, the shaft will keep moving inward until it

is stopped by the internal parts such as the pilot bearing thrust washers

These conditions must be prevented

Power Take-Offs

Refer to your owner's manual, installation procedures, and safety precaution when installing any PTO on your transmission

When installing the front bearing retainer and seal in

the transmission, use the red plastic sleeve to prevent

serious damage to the oil seal Failure to use the seal sleeve

will void the seal warranty

GENERAL DISASSEMBLY

Section III

Front Bearing Retainer & Seal

Hydrodynamic Lip Seal must be installed so that Hydrodynamic Lip faces toward inside of transmission.

Remove seal cardboard shipping tube or plastic installation sleeve just prior installing bearing cap assembly to transmission

Push sleeve over end of shaft install bearing cap assembly

After red sleeve is in place install seal dry

MODELS:

12

PS 9/10

Trang 15

SHIFT TOWER DISASSEMBLY

Section IV

1 Cut the tie-down straps and lift the boot off the lever.

2 Holding the lever in a vise, Remove the tower snap ring.

3 Pull the lever, the upper and lower plastic sockets, and the

two opposing springs from the tower.

MODELS:

13

PS 9/10

Trang 16

REMOTE CONTROL DISASSEMBLY

Section V

1 Remove the six bolts Separate the remote

control from the Transmission.

2 Disconnect the tie rod from the housing and the

selection lever.

3 Disconnect the selection lever from the outer

shift lever.

4 Remove the bolts from the outer shift lever Tap

the lever off the shift rod.

5 Cut the tie straps from the boot and remove it.

6 Remove the shift finger bolts and tap the finger off the rod.

7 Pull the rod from the housing.

8 To d i s a s s e m b l e t h e s e l e c t i o n l e v e r subassembly, first remove the snap ring and retainer plate.

9 The bearing race, ball stud, and a final bearing race are removed next.

10 Remove the two springs and the boot.

MODELS:

14

PS 9/10

Trang 17

RANGE CASE DISASSEMBLY

Section VI

Range Case Exploded Drawing

MODELS:

15

PS 9/10

Trang 18

Section VI

Range Gears Exploded Drawing

MODELS:

16

PS 9/10

Trang 19

1 Begin the teardown by setting the transmission on a bench

Remove the shift tower and air lines

2 To remove an air line from a fitting like the one shown here, push the bushing in with a small screwdriver or your fingernail and pull the tubing

5 Remove the backup light switch and pin

3 Remove the interlock plate, retainer and gasket Also remove the

three springs and poppet balls

4 Next remove the air control valve and gasket, the air lines, and the three interlock pins

Section VI

MODELS:

17

PS 9/10

Trang 20

6 Remove the two clutch housing bolts from the case Also remove

all but four clutch housing-to-case bolts

7 Stand the transmission on end on a workbench that

contains a hole for the drive gear Lift the transmission with a

11 Remove the output bearing cap and shims

18

PS 9/10

Trang 21

12 Remove the range case bolts Using pry bars in the milled slots

will make case removal easier

13 Use a chain hoist to lift the range case from the unit

14 The output shaft and low range gear will remain with the range

case Remove the range synchronizer and fork assembly

15 Be aware that separating the synchronizer will suddenly release the springs Always wear safety glasses to protect your eyes when servicing transmissions Synchronizer replacement parts may

be purchased separately

Section VI

16 Remove retaining bolt and washer, next remove the

synchronizer cup and high range clutch gear

MODELS:

19

PS 9/10

Trang 22

18 Remove shift bar support bracket.

19 Simultaneously lift both countershafts straight up to

remove them Now remove the mainshaft reverse gear and rear

thrust plate together

20 Remove the retaining bolt and washer then remove the countershaft reverse gears

Section VI

17 Lift high range gear from the case

21 Remove the oil pump housing screws, next remove oil pump

assembly

MODELS:

20

PS 9/10

Trang 23

22 Remove the left countershaft retaining bolts and retaining

plates Also remove the oil passage bypass valve

23 Next remove the right countershaft rear bearing retainer plates and shims

25 Remove the output shaft bearings from the case Wearing

A safety glasses, press the inner bearing from the shaft

26 These bearings and spacers are a matched set If it is

necessary to replace any of the components, the whole set must be

replaced Replace them as a set to help ensure proper end play

GEARS & RELATED PARTS

Section VI

MODELS:

24 Remove the output shaft from the case

21

PS 9/10

Định dạng
Số trang	47
Dung lượng	5,06 MB